International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 03 Issue: 09 | Sep-2016 www.irjet.net p-ISSN: 2395-0072

Effect of Fly Ash on Corrosion Potential of Steel in Concrete

Nithya P.S1, Dr. George Mathew2
1PG student, Indira Gandhi Institute of Engineering and Technology for Wome, Nellikuzhy, Kerala, India,
nithyasoman123@gmail.com,Mob No:08547299740
2Professor, Division of Safety and Fire Engineering, School of Engineering, Cochin University of Science and Technology, Kochi,
Kerala, India, cusat.george@gmail.com, Mob No: 09447726194

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Abstract –This paper presents the details of a study on
the effect of fly ash on the corrosion potential of steel in
concrete. The variables considered include fly ash content
(15% and 20%) and w/b ratio (0.40 ,0.45 and 0.50).
Concrete specimens of size 280mm ×150mm× 115 mm were
cast with different mix proportions based on the variables
considered. The total content of cementitious material was
kept at 300 kg per cubic meter of concrete. Alternate
wetting and drying method with 3% NaCl solution was
adopted to study the corrosion potential of steel in concrete.
Total corrosion current was calculated as per the ASTM
standard for a period of 120 days. Based on the study, it
could be concluded that, by properly selecting the
replacement quantity of fly ash (20%) and w/b ratio
(0.40), the corrosion potential of steel in concrete
could be reduced very much and at the same time the
strength properties could be enhanced.
Key Words: Corrosion, Chloride induced corrosion, Fly
Ash, Accelerated corrosion technique, Alternate wetting
and drying, Macrocell corrosion test.
1. INTRODUCTION
Structural concrete is the widely used material in
construction. However, the corrosion in steel embedded in
concrete is a major factor causing distress to the concrete
structures. The cracking and spalling of concrete
associated with corrosion in reinforcement is a major
concern in areas with marine environments and in areas
where deicing salts are used. Corrosion of steel embedded
in concrete plays a vital role in the determination of life
and durability of the concrete structures [1]. Different
methods are being adopted to reduce the corrosion
potential of steel in concrete such as, cathodic protection,
surface treatment of rebars, surface treatment of concrete
surface, use of corrosion inhibitors in concrete, and the
use of mineral admixtures in concrete[2].
The most common mineral admixtures used in concrete
include Silica Fumes, Ground Granulated Blast Furnace
Slag, and Fly Ash[3]. These admixtures are produced from
the waste materials generated by silicon metal industry,
steel industry and coal thermal power plants, respectively.
Theses mineral admixtures are being widely used in
concrete in specified quantities to improve various
physical properties of concrete.
Production of fly ash from thermal power plants is a major
environmental issue and its disposal by using in concrete
production has been studied extensively in the past two
decades. Depending on the content of calcium, fly ash is
classified into class C and class F by ASTM [4] and each
type has its own role to play in improving the physical
properties of concrete like workability, permeability,
durability, resistivity, resistance to chloride intrusion,
carbonation, etc.. [5-13]
In general, a good quality concrete, designed with
sufficient cement content and low water to binder ratio,
reduces the permeability of concrete and hence reduces
the corrosion potential of embedded steel. However, there
are many ordinary concrete structures being constructed
with poor quality control and with low cement content.
There is only limited study reported in literature
addressing the corrosion potential of embedded steel in
such structures.
Hence, for the present study, an attempt has been made to
understand the effect of class F fly ash on corrosion
potential of steel in concrete with low cement content
(300 kg cement per cubic meter of concrete) and with
varying water to binder ratios (0.40, 0.45 and 0.50).
2. EXPERIMENTAL STUDY
2.1 Materials
Cement used was of 53 grade Ordinary Portland
Cement. The physical properties of cement tested as per
the Indian Standard specifications are given in Table 1.
The class F fly ash used had a specific gravity of 2.03.
Crushed granite coarse aggregate of nominal size 12
mm and manufactured fine aggregate (crushed granite)
was used for the present study. The physical properties of
fine and coarse aggregates are presented in Table 2.
Super plasticizer with a commercial name Conplast
SP430 was used to make concrete workable.

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Volume: 03 Issue: 09 | Sep-2016 www.irjet.net p-ISSN: 2395-0072

Table -1: Physical properties of cement concrete; W1, W2 and W3 stands for the water binder
ratios of 0.40, 0.45 and 0.50 respectively.
IS Specification
SL NO Properties Obtained value 2.3 Specimen Preparation
1 Specific gravity 3.01 IS:2720(Part 3)
The various ingredients for concrete were mixed
Standard consistency 33% IS:4031(Part 4)
in a pan mixture .Slump test was carried out to ensure
2
uniformity in the concrete mix.The specimen for corrosion
test was prepared as per the ASTM standard [ 15]. Concrete
3 Initial setting time(minutes) 41 IS:4031(Part 5) prisms of size 280 mm × 115 mm × 150 mm (L x Wx H)
were prepared in specially prepared steel moulds. Before
4 Final setting time(minutes) 193 IS:4031(Part 5) placing concrete in the mould, two 12 mm diameter HYSD
reinforcing bars were placed at 25 mm from the bottom of
the mould (cathode) and one bar was placed at 25 mm
Table -2: Physical properties of aggregate from the top (anode). These bars were initially insulated
with an epoxy coating as per the ASTM guidelines.
Value
Properties Coarse aggregate
Fine aggregate Concrete was placed in the moulds in three layers
Specific gravity 2.95 2.71
and compacted with the help of a table vibrator. The
Fineness modulus 2.46 --
specimens were demolded after 24 hours from the time of
Water absorption 3.2 0.29 casting and were kept in curing tank for another 27 days.
Standard cubes of size 150 mm were also prepared along
The reinforcement bars used for the test was TMT with the prisms for the determination of the concrete
HYSD bars of 12 mm dia. Potable water was used for strength on 28th day.
making concrete as well as for curing of specimens.
After 28th day from the date of casting, the top
2.2 Mixture proportion surface of the prism was roughened with the help of a
steel wire brush and kept in the laboratory environment
Mixture proportions have been arrived based on the for normal drying of the specimen. After two weeks from
Indian Standard code of practices [14]. Based on the the date of keeping the specimen outside the curing tank,
different variables considered for the present study, nine the four vertical sides of the concrete prism were coated
mixture proportions were prepared and Table 3 presents with epoxy. A dam of size 150mm × 75mm × 75 mm was
the quantities of constituent material required for one made with Perspex sheet and was then fixed centrally over
cubic meter of concrete. the top of the roughened face. The top surface outside the
dam was then coated with epoxy. One end of the rebar
Table -3: Quantities of materials per cubic meter of was soldered with a copper wire and a 100 ohm resistor
concrete was placed between the top and bottom bars. Figure 1
Fly Fine Coarse Super
Cement Water
Mix ID
(kg)
ash aggregate aggregate plasticizer
(L)
shows the typical photograph of corrosion test specimen
(kg) (kg) (kg) (kg)
CCW1 300 0 746.43 1313.31 6.0 117.75
ready for the test.

CCW2 300 0 731.19 1286.49 6.0 131.4

CCW3 300 0 716.44 1260.56 6.0 146.4

F1W1 255 45 738.86 1299.98 6.0 116.4

F1W2 255 45 724.11 1274.07 6.0 131.4

F1W3 255 45 709.37 1248.11 6.0 146.4

F2W1 240 60 736.49 1295.84 6.0 116.4

F2W2 240 60 721.76 1269.9 6.0 131.4

F2W3 240 60 707.01 1243.97 6.0 146.4

Here, CC stands for control concrete; F1 and F2

Fig. 1: Corrosion test specimen
stands for respectively 15% and 20% of Fly Ash in

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2.3 Corrosion test
After 30 days from the date of removal of specimen from
the curing tank, the corrosion test was started. The test
specimens were kept on two non-electrically conducting
supports to ensure air flow under the specimen.
One test cycle consists of wetting the specimen by
filling the dam with 3% NaCl solution to a height of about
40 mm for two weeks and then removing the salt solution
by vacuuming out and keeping the specimen in dry
condition for another two weeks. A plastic loose fitting
cover was placed on top of the dam to minimize
evaporation of the salt solution. This cycle of wetting and
drying was continued till 120th day.
Voltage readings across a 100 Ω resistor were
taken at the beginning of the second week of ponding with
the help of a voltmeter. The current through the resistor,
Ij, could be calculated from the measured voltage, Vj, using
the equation
ij = Vj /100
The total integrated macrocell current over a time period,
which is a measure of corrosion potential of embedded
steel in concrete, was then calculated using the relation
Tcj = Tcj-1 + [(tj-tj-1) × (ij + ij-1)/2]
Where
Tc = total corrosion current (coulombs)
tj = time (in seconds) at which measurement of the
macrocell current was taken, and
ij = macrocell current (amps) at time, t j
Figure 2 shows the corrosion test specimen showing the
method of measurement of voltage across the resistor.
Fig. 2: Macrocell corrosion test set up showing voltage
measurement
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3. RESULTS AND DISCUSSIONS
A total of 27 corrosion test specimen and cubes
were prepared for the present study. Each value in tables
and figures is the average of three test results.
Chart 1 shows typical graph showing the variation of 28th
day cube compressive strength of concrete with w/b ratio.
It could be observed from chart 1 that, the effect of w/b
ratio on strength of concrete follows Abram’s law in all the
three mixes considered.
Chart -1: Variation of 28th day cube compressive strength
of concrete with w/b ratio
Further, the addition of Fly ash enhances the compressive
strength of concrete. It could also be observed that, 20%
fly ash content in concrete gives maximum enhancement
in compressive strength and depending on the w/b ratio,
its value ranges from 15% to 22%.
Chart 2 shows the corrosion potential of steel in concrete
expressed in terms of total corrosion current for varying
percentage of fly ash and for a w/b ratio of 0.40.
Chart -2: : Variation of total corrosion current with time
for concrete with fly ash and for a w/b ratio of 0.40
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Charts 3 and 4 shows the corrosion potential of
steel in concrete for a w/b ratio of 0.45 and 0.50
respectively. For the present study, the corrosion
potential of reinforcement in concrete has been studied
for a period of 120 days and Table 4 shows the total
corrosion current in specimens obtained at 120th day.
From charts 2 to 4, it could be observed that, the
water to binder ratio is the primary factor causing
corrosion steel in concrete .The specimens with w/b ratio
of 0.4 shows less corrosion potential where as specimen
with a w/b ratio of 0.5 shows higher corrosion potential.
It could be observed that the addition of fly ash in
concrete reduces the corrosion potential of steel in
concrete and 20% fly ash in concrete yields lowest
corrosion potential.

For the present study, with 300 kg cementitious

material per cubic meter of concrete, the corrosion
potential of steel in concrete could be reduced by about
71% when 20% cement is replaced with fly ash and with a
w/b ratio of 0.40.

4. CONCLUSIONS

Based on the study conducted on concrete mixes having

Chart -3: Variation of total corrosion current with time 300 kg cement per cubic meter of concrete and with 15%
for concrete with fly ash and for a w/b ratio of 0.45 and 20% fly ash as replacement of cement, following
conclusions could be derived.

 Irrespective of the w/b ratio considered (0.40 to

0.50) the replacement of OPC with fly ash
improves the compressive strength of concrete

 For the present study, compared with OPC

concrete having a w/b ratio of 0.40, a maximum
enhancement in cube compressive strength of
22% could be achieved when cement was
replaced with 20% fly ash.

 Concrete with higher water to binder ratio will

lead to a higher corrosion potential in embedded
Chart -4: Variation of total corrosion current with time for steel.
concrete with fly ash and for a w/b ratio of 0.50
 Use of fly ash in concrete reduces the corrosion
Table 4: Total corrosion current on 120th day potential of steel in concrete.

SL No
Mix ID
Total corrosion  The total corrosion current on 120th day’s
current, Tc ( C )
1 CCW1 5.21
observation was lowest for the concrete with
20% fly ash content and for a w/b ratio of
2 CCW2 10 0.40. This is about 71% less compared to the
3 CCW3 38.9 corresponding specimen with OPC.
4 F1W1 3.63
Based on the present study, it can be
5 F1W2 4.54 concluded that, by properly selecting the
replacement quantity of fly ash (20%) and w/b ratio
6 F1W3 12.54
(0.40), the corrosion potential of steel in concrete
7 F2W1 2.65 could be reduced very much and at the same time the
strength properties could be enhanced.
8 F2W2 2.98

9 F2W3 10.13

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ACKNOWLEDGEMENT by EIS”, Cement & Concrete Composites,

This study was carried out with the financial support from
Kerala State Council for Science, Technology and
Environment under the research project No.
ETP/10/2012/KSCSTE.
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